Details

The Fuel Consumption Measurement System (FCS) is a highly advanced, self-contained, skid-mounted system designed specifically for testing the fuel consumption of locomotives. This system offers precise, real-time monitoring and accurate measurement of fuel usage as it continuously tracks the mass of fuel in the tank, ensuring efficiency in locomotive fuel consumption testing. With sophisticated components such as fuel filtration, temperature control, and weighing systems, the FCS is an essential tool for performance testing and fuel efficiency analysis.

System Components
1. Fuel Tank
2. Material: Stainless Steel (SS-304)
3. Capacity: 150 liters (usable fuel volume)
4. Design: The tank stores the fuel, which is then pumped to the test engine via the filtration system. The tank is mounted on four load cells, which continuously monitor the weight of the fuel inside the tank. These load cells send signals to the control system, providing accurate fuel consumption data.
5. Tank Weighing System (TWS)
6. Components: The TWS consists of four load cells, a flameproof junction box, and a Mettler Toledo IND 570 indicator.
7. Function: The load cells measure the mass of the fuel tank and the fuel inside it. As fuel is consumed by the test engine, the mass of the tank decreases, and the system records these changes in real-time. This allows for accurate monitoring of fuel consumption.
8. Communication: Data from the load cells is transmitted to the PLC for processing and real-time tracking of fuel consumption.
9. Fuel Filling System
10. Electric Motor: A flameproof three-phase electric motor (1.5 kW, 1440 RPM) operates thefuel filling pump.
11. Fuel Pump: The fuel is pumped into the tank under controlled conditions, ensuring smooth operation.
12. Ball Valves:
13. A manual ball valve at the suction of the fuel tank filling pump, with a limit switch ensuring the valve is open before fuel filling starts.
14. An electrically operated ball valve at the outlet of the pump, controlled by the PLC, with a feedback system that confirms the valve’s position.
15. Filtration: A 10-micron filtration system ensures that only clean fuel enters the system, with an indicator to alert the operator if the filter becomes clogged.
16. Relief Valve: A relief valve maintains the pressure within the fuel circuit, ensuring smooth operation and preventing system damage.
17. Temperature Control and Monitoring
18. RTD Sensors: Resistance Temperature Detectors (RTDs) are installed at key locations to monitor the temperature of the fuel and chilled water. The sensors ensure that the fuel temperature remains within a specified range for accurate testing.
19. Shell & Tube Heat Exchanger: The heat exchanger cools the fuel, ensuring it does not overheat during testing. The system maintains the fuel temperature at 85±5°F.
20. Chiller: A three-phase refrigerated air-cooled chiller (12TR capacity) cools the fuel and the water during operation, helping to maintain optimal conditions for testing.
21. Fuel Temperature Control Valves: Two control valves regulate the fuel temperature at the inlet and outlet points, ensuring the temperature stays within the desired range for testing.
22. Control Panel (CP)
23. Design: The CP is housed in a powder-coated metallic enclosure (700x650x350 mm), offering protection for critical components like the PLC controller, Human-Machine Interface (HMI), emergency switch, and tower light.
24. PLC Controller: The PLC manages and controls all system functions, including the operation of pumps, valves, sensors, and temperature control. It communicates with all connected components to ensure proper operation and data exchange.
25. Mettler Toledo IND 570 Indicator: This indicator is used to display real-time data from the load cells and monitor the fuel tank’s mass.
26. HMI: The HMI on the control panel displays live data, including the status of all components in the fuel circuit (open/close, on/off). It provides a user-friendly interface for operators to control system functions.
27. Chiller System
28. Cooling Function: The chiller cools the fuel, preventing overheating during testing. This is crucial for maintaining accurate test conditions.
29. Temperature Control: The chiller system includes sensors to monitor the temperature of the fuel and chilled water, ensuring the fuel remains at the desired temperature.
30. Communication: The PLC communicates with the chiller system via RS485 to manage its operation.

Technical Specifications
Below are the detailed technical specifications for the Fuel Consumption Measurement System(FCS):

Component Specification
 • Fuel Tank SS-304, 150 liters capacity
 • Electric Motor 1.5 kW, 1440 RPM, 3-phase, Flameproof, 50 Hz
 • Fuel Pump Flameproof motor-driven pump
 • Fuel Filter 10 Micron (absolute), with electronic clogging indicator
 • Load Cells 4 load cells, connected to Mettler Toledo IND 570
 • Temperature Sensors (RTD) 0°C to 100°C, monitoring fuel and chilled water
 • Shell & Tube Heat Exchanger 0.01 Bar pressure drop
 • Chiller 12 TR, three-phase air-cooled, refrigerated system
 • Control Panel 700x650x350 mm, PLC controller, HMI, emergency switch
 • Communication Protocol RS485 (for chiller, TWS), Ethernet (for GE DACS)
 • Safety Features Filter Clogging Indicator, Float Switches, Safety Interlocks
 • Power Supply 220V AC, 24V DC (output)
 • Valve Types Manual and Electrically Operated Ball Valves with limit switches

Operational Features
1. Fuel Consumption Measurement:
2. The system uses load cells to measure the fuel tank’s mass continuously. As fuel is consumed by the locomotive engine, the tank’s mass decreases, and the system records these changes. This allows for accurate real-time fuel consumption monitoring.
3. Fuel Filling Operation:
4. The system includes both local and remote operation modes. The operator can initiate fuel filling through the HMI. The PLC ensures that the correct valves are open before starting the fuel pump. If the tank reaches the maximum fuel weight, the system automatically stops the filling process.
5. Safety Features:
6. Filter Clogging Indicator: Alerts the operator when the fuel filter is clogged.
7. Float Switches: Detect overfill or overflow in the fuel tank.
8. Ball Valves: Manages fuel flow with limit switches ensuring the correct valve positions.
9. Safety Interlocks: The motor will only start when the correct valves are open, and it will stop automatically if the fuel tank mass reaches the preset maximum.
10. Real-Time Monitoring:
11. The HMI displays the operational status of all components in the fuel circuit, including fuel tank mass, valve status, and pump operation. It provides operators with a clear view of the system's performance.
12. System Diagnostics and Calibration:
13. The system includes sensors for diagnostics and monitoring, allowing for system health checks and regular calibration of the TWS to ensure accuracy.

Applications
The Fuel Consumption Measurement System is designed for use in the railway and locomotive industries to monitor and test the fuel efficiency of locomotives. It ensures that fuel consumption is accurately measured, helping operators optimize fuel use and reduce operational costs. It is also critical for validating engine performance under various operational conditions.

Conclusion
The Fuel Consumption Measurement System (FCS) is an essential tool for the railway and locomotive industries, providing precise, real-time measurements of fuel consumption. With its advanced control panel, automated fuel filling system, safety features, and accurate mass measurement capabilities, the FCS helps operators optimize fuel usage, improve efficiency, and enhance overall engine performance.